Collapsible double walled cartons



Aug. 22, 1961 Ml wlLLlAMsON 2,997,220

- COLLAPSIBLE DOUBLE WALL-ED CARTONS Filed DGO. 2, 1955 5 Sheets-Sheet 1 Fay. 2

INVENTOR. Mars/1a!! l lW//z'amson Bydwzdua/ ATTORNEY Aug. 22, 1961 M. l. WILLIAMSON 2,997,220

COLLAPSIBLE DOUBLE WLLED CARTONS Filed Dec. r2, 1955 5 sheevs-sheet 2 Marsha/l l. Wil/am son m: /9 BY Z ATTORNEY Aug. 22, 1961 M. l. WILLIAMSON 2,997,220

coLLAPsIBLE DOUBLE WALLED cARToNs Filed Dec. 2, 1955 3 Sheets-Sheet 3 a f2 w i' f6 IN V EN TOR. Mars/ml! f Williamson ATTORNEY United States Patent O 2,997,220 'COLLAPSBLE DUBLE WALLED CARTONS Marshall I. Williamson, New Haven, Conn., assigner to Federal Paper Board Company, Inc., Bogota, NJ., a corporation of New York Filed Dec. 2, 1955, Ser. No. 550,556 it) Claims. (Cl. 229-14) This invention relates to collapsible double walled cartons and more particularly to cartons formed from one piece blanks presenting when assembled and erected, a rectangular shaped inner sleeve for the reception of a bottle or like fragile article, all contained within and held in spaced relation to an outer rectangular shaped protective sleeve.

Double walled cartons having inner and outer sleeves for cushioning and protecting fragile articles contained therein are well known in the art. Double walled or article cushioning cartons made and used prior to this invention have also been fonned from one piece blanks. However, the prior blanks from which cushioned cartons are formed must either be assembled around the article contained therein or around a forming mandrel, or if they can be assembled by collapse folding, require the use of ten panels to provide full cushioned spacing of the inner sleeve within the outer sleeve, or if formed from only nine panels, result in the formation of an inner sleeve one of whose panels is directly adjacent and adhesively secured to a corresponding panel on the outer sleeve so that the article contained therein is not adequately cushioned and protected.

The prior double walled cartons which require mandrel assembly, provide a costly packaging medium since the assembly operation must be largely performed by hand. The collapsible type of prior cushioned cartons either fail to provide the desired cushioning along one side of the carton, or otherwise require an excessive amount of paperboard to form its ten panels. The assembly of the prior collapsible type of cushioning cartons has also required two separate gluing operations, or slow and cumbersome folding operations, or are so constructed that they are diiicult to erect when assembled in collapsed form.

This invention is directed to a solution of the drawbacks and diiculties of the prior double Walled cartons. The double walled carton of this invention can be assembled in collapsed form automatically and at higher speed than the prior cartons. It is assembled from a novel and improved blank which requires less stock sheet material than heretofore required, is designed to insure positive and accurate folding of the successive panels during its uninterrupted run through a high speed folding and gluing machine, and requires only a single strip gluing operation to fully yassemble the same in collapsed form. The carton forming blank is so formed and dimensioned that when the carton is erected, the four panels which constitute the inner sleeve are positively maintained in spaced and cushioned relation to the surrounding outer sleeve panels.

This improved double walled carton is so constructed as to insure positive erection of the collapsed carton when squeeze pressure is exerted against the opposite side edges thereof. It inner and outer sleeves will positively swing into rectangular position without drag or interference, and its four inner sleeve panels when erected are resiliently maintained in rectangular position to provide a smooth walled inner sleeve into which the bottle or like fragile article may be machine inserted without interference from projecting edges and corners. This invention also embraces an improved method of assembling collapsed double Walled cartons from one piece blanks.

Other objects and advantages of this invention will become apparent as the disclosure proceeds.

Although the characteristic features of this invention will be particularly pointed out in the claims, the invention itself, and the manner in which it may be carried out, may be better understood by referring to the following description taken in connection with the accompanying drawings forming a part hereof, in which:

FIG. 1 is a plan view showing the inside face of the one piece blank from which this improved collapsible double walled carton is assembled;

FIG. 2 is a transverse cross section of the blank as the same would appear when viewed along line 2--2 of FIG. l with the outside face of the blank uppermost. This view more fully illustrates the formation of the segmental scores and continuous scores which define the panels of the inner and outer sleeves of the blank;

FIG. 3 is a plan view of the inside face of the blank of FIG. l as it would appear after completion of the first folding operation, and wherein the rst and second inner sleeve panels have been folded into adjacent overlying relation to the third and fourth inner sleeve panels;

FIG. 4 is a plan view of the blank as it would appear after completion of the second folding operation and wherein the first and second inner sleeve panels have been again folded into adjacent overlying relation to the inner and outer sleeve connecting panel and the rst outer sleeve panel;

FIG. 5 is a plan view of the blank as it would appear after the third folding operation has been completed and wherein the third and fourth inner sleeve panels have been folded into adjacent overlying relation to the second and third outer sleeve panels, this View also showing the adhesive strip applied to the securing section of the inner and outer sleeve connecting panel;

FIG. 6 is a plan View of the blank as it would appear after completion of the fourth and final folding operation and wherein the fourth outer panel has been folded in overlying relation to the connecting panel and pressed into adhesively secured relation to the securing section thereof to thereby provide the collapsed carton in form for shipment to the user;

FIG. 7 is a transverse section of the collapsed carton body as the same would appear when viewed along line 7 7 of FIG. 6;

FIG. 8 is a transverse section of the carton body shown in FIG. 7 and as it would appear when undergoing erection expansion;

FIG. 9 is a transverse section of the carton body shown in FIG. 8 and as it would appear when fully erected, this View serving to illustrate the erected arrangement of the panels of the inner and outer sleeve, the connecting panel, and the foot and head tabs associated with the four inner sleeve panels; and

FIG. l0 is a perspective View of the erected carton having its bottom end closed land its top end open and ready for the insertion of a bottle or other merchandise article to be contained and protected within the inner sleeve thereof.

Similar reference characters refer to similar parts throughout the several views of the drawings and specification.

Collapsible double walled cartons are made in accordance to this invention from a single blank of brous sheet material such as paperboard or flberboard of Suitable thickness. The fibrous stock sheet from which the blanks are taken is of such character and is so cut that the stock `sheet fibers extend transversely of the longitudinal panel defining scores of the blank, whereby the hingedly connected panels of both the inner and outer sleeves will possess sufficient inherent resilience and tendency to swing towards their unfolded planar position when folding pressure is removed therefrom.

Blanks as illustrated in FIG. '1 may be cut and scored in a single pass of the stock sheet through -a cutting and scoring machine equipped with the necessary elements to form the desired cuts and scores therein. The stock sheet need be printed and decorated on one side thereof only, and the printing and decoration may be confined to the outer sleevepanelsonly. The end closure` flaps and end panels associated with the outer sleeve may be so arranged as to insure minimum waste in cutting the blanks from the stock sheet material.

The blank as shown in FIG. 1 is designed to provide an inner sleeve of rectangular cross section as erected, formed by four successively arranged inner sleeve panels 1, 2, 3 and d, and an outer sleeve of rectangular cross section when erected formed by four successive outer sleeve panels 6, 7, 8 and 9, with the fourth inner sleeve panel 4 joined to the first outer sleeve panel 6 by a connecting panel 5. The first inner sleeve panel 1 is integrally hinged to the second inner sleeve panel 2 by a series of spaced and longitudinally aligned score segments 11; the second inner sleeve panel 2 is integrally hinged to the third inner sleeve panel 3 by similar spaced and longitudinally aligned score segments 12; the third inner sleeve panel 3 is integrally hinged to the fourth inner sleeve panel 4 by similar spaced and longitudinally aligned score segments 13; and the fourth inner sleeve panel 4 is integrally hinged to the adjacent inner and outer sleeve connecting panel 5 by lsimilar spaced and longitudinally aligned score segments 14.

The rst outer sleeve panel 6 is integrally hinged to the inner and outer sleeve connecting panel 5 by a continuous and longitudinally extending score 16; the first outer sleeve panel 6 is integrally hinged to the second outer sleeve panel 7 by a continuous and longitudinally extending score 17; the second outer sleeve panel 7 is integrally hinged to the third outer sleeve panel 8 by a continuous and longitudinally extending score 18; and the third outer sleeve panel 8 is integrally hinged to the fourth outer sleeve panel 9 by a continuous and longitudinally extending score 19.

The inner and outer sleeve connecting panel 5 is divided into a spanner section 5 and a securing section 5 integrally hinged together by a continuous and longitudinally extending score 15. The score 15 is so positioned that the Spanner section 5', as defined between the score segments 14 and the continuous score 15, is substantially wider than the securing section 5 as defined between the adjacent continuous scores 1S and 16. The score segments 11, 12, 13 and 14 and continuous lscores 15, 16, 17, 1S and 19 are in accurate parallelism with each other and also with the straight and uninterrupted free longitudinal edge 1@ of the rst inner sleeve panel 1 and the straight and uninterrupted free llongitudinal edge 20 of the fourth outer sleeve panel 9. lt will be noted by referring to FiGS. 1 and 2 that the segmental scores and the continuous scores are each defined by -a pair of closely adjacent parallel bend lines and that all the scores are impressed into the blank from the outer face thereof so that projecting beads are formed on the inside face and depressions are formed on the outside face of the blank, with the beads and depressions defined between the bend lines. The blank is so cut that the stock sheet fibers extend transversely across the score segments 11, 12, 13 and 14 and the continuous scores 15, 16, 17, 13 and 19 so that when the panels hinged thereby are folded to present their inside faces in adjacent relationship, the inherent resiliency of the scoring will have a tendency to restore the folded panels to Itheir coplanar position when the folding pressure is released. It will be noted, however, that one of the continuous scores, namely score l5 within the connecting panel Si, is partly broken by spaced cuts 1S therein so as to substantially destroy its inherent resiliency.

Provision is made for maintaining the four panels of the inner sleeve of the erected carton in spaced and parallel relation to the corresponding four outer panels of the outer sleeve to provide the desired cushioning of the fragile article to be inserted into the inner sleeve. This is effected by the provision of head tabs 11 and alternating foot tabs 11 which alternately join the adja` cent ends of the score segments 11; by head tabs 12 and alternating foot tabs 1'2" which join the alternate ends of the score segments 12; by head tabs 13 and alternating foot tabs 13 which join the alternate ends of the score segments 13; by head tabs 14 onlyV which join the adjacent ends of the score segments 14; and finally by the Spanner section 5 of the inn-er and outer sleeve connecting panel 5.

'The longitudinally extending score segments 11, 12, 13 and 14 are of equal longitudinal length and in columnar alignment transversely of the blank. The head tabs 11', 12', and 13' are integral with the respective first, second and third inner `sleeve panels 1, 2, and 3, extend inwardly of the blank as shown in FlG. l, are the same in longitudinal length, and are in columnar alignment transversely of lthe blank. The Afoot tabs 11, 12 and 13 are integral with the respective second, third and fourth inner sleeve panels 2, 3 and 4, extend in an outward direction towards the free longitudinal edge 1t) of the inner sleeve panel 1, are of the same longitudinal length, and are in columnar alignment transversely of the blank. The respective head tabs 11', 12 and t13' and foot tabs 11", 12" and 13" also have substantially the same width as measured transversely of the blank as shown in FIG. l.

While the blank shown in FIG. l makes provision for six sets of transversely aligned score segments 11, 12 and 13, three sets of transversely aligned head tabs 11', 12' and 13', and two sets of transversely aligned `foot tabs 11, 12" and 13 which alternate with the head tabs 11', 12" and 13', it will be appreciated that any desired number of spaced score segments 111, 12 or 13 and alternating head tabs 11', 12' and 13 and foot tabs 11", 12" and 13" may be provided in `accordance with the desired longitudinal length of the inner sleeve panels 1, 2, 3 and 4.

The transverse width of the second inner sleeve panel Z, as defined between the parallel and longitudinal extending score segments 11 and 12', is accurately equal to the transverse width of the fourth inner sleeve panel d as defined lbetween the parallel and longitudinally extending score segments 113 and 14. However, it will be particularly noted that the transverse lwidth of the first inner sleeve panel 1, as dened between the straight free edge lll' thereof and the score segments 11, is slightly less than the transverse width of the third inner sleeve panel 3V as measured between the parallel and longitudinally extending score segments 12 `and 13. This imporf tant feature facilitates the lhigh speed and flat collapsed folding of the blank to provide the collapsed carton body as hereafter described.

It will be further particularly noted that the adjacent ends of the longitudinally aligned score segments 14 are joined by head tabs 14 only, and that no foot tabs are associated with the inner and outer sleeve connecting panel 5. The head tabs 14 are the same longitudinal length as the head tabs 11', 12 and 13 and foot tabs 11", 12" and 13, and are in columnar alignment therewith transversely of the blank. The number of head tabs 14 is preferably equal to the sum total of the head tabs 13' and foot tabs 13 associated with the aligned score segments 13. It will be particularly noted that the head tabs 14' have a width transversely of the blank which is slightly less than the transverse width of the head tabs 11', 12' and 13. By making the head tabs 14' of less transverse width than the equal width head tabs 11', 12 and 113 and the correspondingly equal width foot tabs 11, 12'" and 13", the extreme transverse width of the fourth inner sleeve panel 4, as measured between the tip ends of its head tabs 14 and its foot tabs 13, is accordingly slightly less than the extreme transverse Width of the second inner sleeve panel 2 as measured between the tip ends of its head tabs 12 and its foot tabs 11". This important feature further facilitates the high speed collapsed folding of the inner and outer sleeve panels to provide the collapsed carton.

The transverse width of the first outer panel 6, as defined between the parallel longitudinal scores 16 and 17, is accurately equal to the transverse width of the third outer sleeve panel S as defined between the parallel longitudinal scores 1S and 19. The transverse Width of the fourth outer sleeve panel 9, as defined between its longitudinal edge 2f) and the longitudinal score 19, is less by at least the thickness of the stock sheet material, than the transverse width of the second outer sleeve panel 7 as defined between the longitudinal scores 17 and 1S, but the transverse width of panel 9 is nevertheless substantially greater than two-thirds the transverse width of panel 7.

The maximum transverse width of the second inner sleeve panel 2, as measured between the tip ends of its foot tabs 11" and opposite head tabs 12', is closely equal to the transverse inside width of the first outer sleeve panel 6 as measured between its side edge defining scores 16 and 17. The third inner sleeve panel 3 also has a maximum width, as measured between the tip ends of its `foot tabs 12" and opposite head tabs 13', which is closely equal to the transverse inside width of the second inner sleeve panel 7 as defined between its side edge defining scores 17 and 18. However, the extreme transverse width of the fourth inner sleeve panel 4, as defined between the tip ends of its foot tabs 13 and opposite head tabs 14', is slightly less than the transverse width of the third outer sleeve panel 8 as defined between its side edge forming `Scores 18 and 19. rl'hese dimensional attributes are highly important and further measurably contribute to the high speed assembly of the blank into collapsed carton form.

The transverse -width of the inner and outer sleeve connecting panel 5, as measured ybetween the aligned score segments 14 and lthe continuous longitudinal score 16, is greater than the transverse width of the first inner sleeve panel 1, as measured between its free straight edge and the tip ends of its head tabs 11', by a substantial increment. This increased width increment substantially corresponds to the increased length which the hypotenuse of a right angle triangle bears to its longer vertical leg when its shorter base leg is equal to the transverse width of the head tabs 14'; the spanner section 5 constituting the hypotenuse of that triangle.

The outer sleeve forming panels are provided with the usual complement of end closure flaps and panels which form the top and bottom ends of the assembled carton. For example, the bottom and top ends of the second outer panel 7 may be provided with a pair of infolding flaps 27-2'7' which are integrally hinged thereto by transversely extending scores 37-37. rIhe fourth outer sleeve panel 9 may be provided with similar infolding fiaps .Z9-29' integrally hinged to the bottom and top ends thereof as by transverse scores 35i-39. The bottom 4forming panel 26 and top forming panel 26 may both be integrally hinged as by transverse scores 36 and 36 to the first outer sleeve panel 6 as shown in FIG. l, or alternatively, the bottom and top end panels 26-26' may both be hinged by transverse scores to the bottom and top ends of the third outer sleeve panel 8, or as a unther alternative, only one of the end forming panels 26 or 26 may be hinged to :the adjacent end of the first outer sleeve panel 6 and the other end panel hinged to the opposite end of the third outer sleeve panel S. The end forming panels 26-26 may be provided with tuck aps 28-28 respectively hinged thereto along transverse scores 38-38, or the tuck flaps 28--28 may be eliminated and the end yforming panels 26-26 then held in end forming position by gluing the same to the adjacent infolded end flaps 27-29 and 27-29. It will be appreciated that the particular arrangement of the outer end panels 26-26, and the manner in which they are held in closed position, may be varied as desired in accordance with the customers packing requirements.

The outer sleeve panels 6, 7, 8 and 9 may be substantially equal in length, and `of sufficient length to contain the bottle or fragile article to be packaged therein. The inner sleeve panels v1, 2, 3 and 4, and the connecting panel 5, may be of equal length and may have a length which is not greater than, and preferably at least two thicknesses of stock sheet material less than, the length of the outer sleeve panels.

1n assembling the blank shown in FG. l into collapsed carton form, the second inner sleeve panel 2 is folded inwardly along the aligned sco-re segments 12 so as to thereby place the inside faces of the second inner sleeve panel 2 and first inner sleeve panel 1-in adjacent overlying relation to the inside faces of the third and fourth inner sleeve panels 3 and 4 as illustrated in FIGS. 3 and 7. This first folding operation will cause the head tabs 12 and foot tabs 12 to project outwardly from the score segments 12, leaving corresponding shaped openings in the adjacent edges of the second and third inner sleeve panels 2 and 3. By reason of the fact that the transverse width of the first inner sleeve panel 1, as defined between its free edge 19 and score segments 11, is of less transverse width than the transverse width of the third inner sleeve panel 3, as defined between the parallel score segments 12. and 13, the free edge 16 of the first inner sleeve panel 1, when folded to overlie the fourth inner sleeve panel, will extend slightly short of the adjacent score segments 14 as shown in FIG. 3. This is an important feature which facilitates the high speed execution of the second folding operation.

ln the second folding operation as shown in FIG. 4, the blank is folded along the aligned scored segments 14 so as to place the first and second inner sleeve panels I1 and 2 in adjacent overlying relation to the connecting panel 5 and the first outer sleeve panel 6, the fourth and third inner sleeve panels 4 and i3 directly overlying the previously folded first and second inner sleeve panels 1 and 2 as shown in FIGS. 4 and 7. This critical second folding operation can be performed at very high speed on a continuous folding machine While the traveling blank is under downward pressure because of two important features incorporated into this blank; i.e., first, because the straight free 'edge 1f) of the first inner sleeve panel after the first folding operation lies within the boundary of the underlying fourth inner sleeve panel 4, and extends short of, and does not overlap, but nevertheless is closely adjacent to the aligned score segments 14 so as to thereby provide a bending edge which facilitates the second step folding along the aligned score segments 14; and second, because the head tabs 14 projecting integrally from the fourth inner sleeve pane-l 4 are of reduced transverse width and thus do not interfere with the second yfolding operation along the score segments 14.

On completion of the second folding operation as shown in FIG. 4, it will be noted that the tip extremities of the head tabs 12' and foot tabs 12 projecting integrally from the second and third inner sleeve panels 2 and 3 respectively, will all lie within the area of the first outer sleeve panel 6, with the tip ends of the head tabs 12' and foot tabs 12 substantially short of the continuous longitudinal score 17. Accordingly, the third folding operation can be executed without interference and at high speed by folding the first outer sleeve panel 6 along the continuous sco-re 17 so as to place the third and fourth inner sleeve panels 3 and 4 in adjacent overlying relation to the second and third outer sleeve panels 7 and 8 and With the rst outer sleeve panel 6 and connecting panel 5 ydirectly overlying the third and fourth inner sleeve panels 3 and 4, as shown in FIGS. 5 and 7. Upon completion of this third folding operation, it will be particularly noted that the tip ends of the head tabs 14' projecting integrally from the fourth inner sleeve panel 4 and beyond the segmental score 14, will lie within the boundaries of the third outer sleeve panel 8 and will be adjacent to but slightly spaced from the longitudinal score 19, an important condition which is achieved by the fact that the head tabs 14' are of reduced transverse width. This important feature facilitates the continuous high speed execution of the fourth and linal folding operation on the automatic foiding and gluing machine.

Before executing the fourth and final folding operation, an adhesive strip a is applied to the exposed outside face of the securing section of the connecting panel 5, care being taken to confine the glue strip a within the boundaries of the securing section as defined by the longitudinal scores 15 and 16. The glue strip a is automatically applied by the high speed gluing and folding machine during uninterrupted travel of the blank therethrough. The fourth and tinal folding operation is executed by folding the fourth outer sleeve panel 9 along the adjacent longitudinal Vscore 19 so as to overlie the adjacent connecting panel 5, and thereafter pressing the inside face of the fourth outer sleeve panel 9 into adhesively secured relation to the previously glued securing section 5" of the connecting panel 5. As thus assembled, it will be noted that the free longitudinal edge 2b of the fourth outer sleeve panel 9 will extend slightly short of the longitudinal score 16, thereby producing a neat corner construction. This operation completes the assembly of the collapsed carton in the form shown in FIGS. 6 and 7.

Collapsed cartons produced by the method above described can be compressed together in stacked relation so as to occupy minimum space in shipment and storage, and when pressure stacked, each collapsed carton will assume the fully collapsed condition shown in FIG. 7. However, when stacking pressure is removed, the collapsed car-ton will have a tendencey to spring toward the trapezoidal formation as indicated iri FiG. 8. This inherent springing tendency of the collapsed carton results from the `manner in which the scoring is formed and the fact that the stock sheet fibers extend transversely of the score segments 11, 12, 13 and 14 and the continuous scores 15, 16, 17, 18 and 19 so that the score segments and continuous scores are resilient.

The resilient springing tendency possessed by the inner and outer sleeve panels may be better understood by referring to the blank folding sequence shown in FIGS. 3 to 6. For example, it will be noted by referring to FIGS. 5 and 6 that the fourth outer sleeve panel g is machine folded approximately liti)o around the resilient score 19. The inherent resilience of the score 19 tends to cause the fourth outer sleeve panel 9 to spring away from the adjacent outer sleeve panel when the pressure is released. Since the second outer sleeve panel 7 is also machine yfolded approximately 180 on the resilient hinging score 17 as shown in FIGS. 4 and 5, the panel 7 will have an inherent tendency to spring away from the adjacent first outer sleeve panel 6. As a result, the outer sleeve panels 6, 7, 8 and 9 will have a tendency to spring from their original pressure folded position to provide an outer sleeve which will tend to spring toward the trapezoidal form indicated in FiG. 8 when the stacking pressure is released.

It will be noted that the third inner sleeve panel 3 is folded during machine assembly approximately 180 with respect to the inner sleeve panel 2 as shown in FIG. 3, and the inherent resiliency of their joining score segments 12 will tend to cause the third inner sleeve panel 3 to spring away from the second inner sleeve panel 2 when the collapsing pressure is released. It will be further noted that the connecting panel 5 is folded during assembly approximately 180 with respect to the fourth inner sleeve panel 4 as shown in FIG. 4, so that the connecting panel S will also have a resilient tendency to spring away from the inner sleeve panel 4 as propelled by the built-in resiliency of the score segments 14.

It will be further noted that during the folding operation shown in FIG. 3, the first inner sleeve panel 1 remains coplanar with the second inner sleeve panel 2, with the joining score segments 11 unbroken. When pressure is released from the collapsed carton so as to permit it to spring toward trapezoidal form, the irst inner sleeve panel `1 will be forced to fold along the resilient score segments 11, but will nevertheless possess the resilient tendency to maintain its free edge 19 in pressure hugging contact with the adjacent inside face of the spanner section 5. This pressure contact between the free edge 1@ of panel 1 and panel 5 is further enhanced when the carton has been fully erected. As a result, the fully erected inner sleeve maintains its rectangular configuration as shown in FIG. 9. Since the inner surfaces of the four inner sleeve forming panels 1, 2, 3 and 4 are smooth and continuous and free of all inwardly extending project-ions, edges and corners, the machine insertion of the fragile article into the open end of the erected carton can be accurately executed at high speed.

Full expansion of the carton in a rectangular form is effected by the application of squeeze pressure against the opposite scores 17 and 19. Full expansion is facilitated by the fact that all frictional drag to full expansion has been eliminated from the carton. It will be noted that one end of the fourth inner sleeve panel 4 is freely suspended and fully supported in spaced relation to the adjacent outer sleeve panel 8 by the Spanner section 5', without the provision of any foot tabs extending from the spauner section 5' and below the inner sleeve panel 4 to produce frictional resistance to full expansion.

It will be further noted that when the collapsed carton has been permitted to spring toward the trapezoidal form shown in FIG. 8, that the adjacent head tabs 11 and foot tabs 11 associated with the iirst and second inner sleeve panels 1 and 2 will hang in midair, and completely out of contact with the inside faces of the adjacent lirst outer sleeve panel 6 and connecting panel 5. The head tabs 13' and foot tabs 13" associated with the third and fourth inner sleeve panels 3 and A- will also be suspended in midair, and completely out of ccntact with the inside faces of the adjacent outer sleeve panels 8 and 7 as shown in FIG. 8.

The tendency toward trapezoidal expansion of the collapsed carton upon removal of the collapsing pressure nevertheless maintains the tip ends of the head tabs 14' extending from the fourth inner sleeve panel 4 substantially in contact with the inner face of the fourth outer sleeve panel 9. Likewise, the tip ends of the adjacent head tabs 12. and foot tabs 12", extending respectively from the second and third inner sleeve panels 2 and 3 as shown in FIG. 8, will be pressed into leverage contact with the adjacent inside faces of the second and first outer sleeve panels 7 and 6 to thereby brace the inner sleeve during pressure expansion without frictional drag. However, unless the squeeze pressure along the outer faces of the hinging scores 17 and 19 is maintained, the carton will partly collapse toward the trapezoidal form as shown in FIG. 8.

Collapsible double walled cartons formed and assembled in accordance with the teachings of this invention present a four walled inner sleeve positively maintained in spaced relation to a four walled outer sleeve to provide rectangular inner and outer sleeves when the carton is erected. The opposite panels of the inner and outer sleeves have corresponding transverse widths, but the carton as erected may have a square cross section or a parallelogram cross section with adjacent panels of different transverse widths. Double walled cartons constructed in accordance with this invention require a minimum of paperboard material, require only a single gluing operation, and can be assembled from one piece blanks into collapsed form by a single pass of the blanks through a straight line gluing and folding machine in continuous fiow at high production speeds, and when the collapsing pressure is released, the collapsed carton will tend to spring into trapezoidal form which greatly facilitates machine erection thereof.

These improved double `vvalled cartons are admirably adapted for high speed packaging in the available automatic loading machines. As the successive collapsed cartons move into the loading machine they will tend to spring toward the trapezoidal form shown in FIG. 8. Squeeze pressure applied to the sprung carton along the opposite hinging scores 17 and 19 only, produces rectangular expansion of the carton into the form shown in FIG. 9. As the erected carton moves through the loading machine, the bottom end fiaps 27-29 are inturned and the bottom end panel then secured in position by insertion of the tuck flap 28 or by adhesively securing the end panel 26 to the inturned end flaps 27 29. When the bottom end of the carton has thus been formed, the fragile article is inserted through the open end of the rectangular inner sleeve, an operation which is greatly facilitated by the fact that the inner surfaces of the inner sleeve forming panels are smooth and finished and not interrupted by projecting end edges, corners or other irregularities. Upon insertion of the article, the top end of the carton is machine closed by inturning the top flaps 27-29 and folding and securing the top end panel 26 in closed position.

While certain novel features of this invention have been disclosed herein and are pointed out in the claims, it will be understood that various omissions, substitutions and changes may be made by those skilled in the art without departing from the spirit of this invention.

What is claimed is:

l. A one-piece, fibrous sheet blank designed when assembled and erected to form a double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve; said blank presenting four inner sleeve forming panels and four outer sleeve forming panels and a connecting suspension panel therebetween; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other and defining the longitudinal edge extremities of the blank; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which dene the adjacent innerface corners of the inner sleeve as assembled and erected; said connecting panel and said first, second, third and fourth outer sleeve panels having the adjacent longitudinal edges thereof integrally joined by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends of their respective score segments joined by cuts defining inwardly extending head tabs and alternating outwardly extending foot tabs of substantially equal transverse Width and providing Spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in spaced relation to the adjacent outer panels of the erected outer sleeve; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which extend inwardly of the blank and of lesser transverse width, by a width increment equal to the blank thickness, than the head and foot tabs associated with said first, second and third series of aligned score segments.

2. A one-piece, fibrous sheet blank designed when assembled and erected to form a double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve; said blank presenting four inner sleeve forming panels and four outer sleeve `forming panels and a connecting suspension panel therebetween; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other and defining the longitudinal edge extremities of the blank; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve as assembled and erected; said connecting panel and said first, second, third and fourth outer sleeve panels having the adjacent longitudinal edges thereof integrally joined by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends of their respective score segments joined by cuts defining inwardly extending head tabs and alternating outwardly extending foot tabs of substantially equal transverse width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in spaced relation to the adjacent outer panels of the erected outer sleeve; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which extend inwardly of the blank and of lesser transverse width, by a width increment equal to the blank thickness, than the head and foot tabs associated with said first, second and third series of aligned score segments; the transverse width of said second inner sleeve panel, as defined between the first and second series of aligned score segments, being the same as the transverse width of said fourth inner sleeve panel as defined between the third and fourth series of aligned score segments; said first inner sleeve panel having a transverse width, as defined between its straight free edge' and the first series of aligned score segments, which is lesser, by an increment substantially equal to the blank thickness, than the transverse width of the third inner sleeve panel as defined between the second and third series of aligned scored segments; whereby said free straight edge of said first inner sleeve panel will lie within the boundari of the fourth inner sleeve panel and in adjacent but nonoverlapping relation to the fourth series of aligned score segments when said second and first inner sleeve panels are folded along the second series of aligned sco-re segments and into adjacent overlying relation with respect to said third and fourth inner sleeve panels.

3. A one-piece, fibrous sheet blank designed when assembled and erected to form a double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve; said blank presenting four inner sleeve forming panels and four outer sleeve forming panels and a connecting suspension panel therebetween; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other and defining the longitudinal edge extremities of the blank; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve as assembled and erected; said connecting panel and said first, second, third and fourth outer 1l sleeve panels having the adjacent longitudinal edges thereof integrally joined by continuous longitudinal scores extending in parallel relation to each othe-r and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends of their respective score segments joined by cuts defining inwardly extending head tabs and alternating outwardly extending foot tabs of substantially equal transverse Width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in spaced relation to the adjacent outer panels of the erected outer sleeve; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which extend inwardly of the blank and of lesser transverse width, by a width increment equal to the blank thickness, than the head and foot tabs associated with said first, second and third series of aligned score segments; said aligned score segments and said continuous scores each being defined by a pair of adjacent parallel extending bend lines pressed into the outer face of the blank to provide therebetween a bead for-mation projecting from the inner face of the blank with the stock sheet fibers extending in a direction substantially transversely of the score segments and continuous scores; said connecting panel being'divided, by a longitudinally extending dividing score parallel to said continuous scores, into a spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a securing section of lesser transverse width hinged by the adjacent continuous score to said `first outer sleeve panel; said connecting panel dividing score having space cuts therein of sufiicient number and length to break the resiliency of said dividing score.

4. A one-piece, fibrous sheet blank designed when .asasembled and erected to form a double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve; said blank presenting four inner sleeve forming panels and four outer sleeve forming panels and a connecting suspension panel therebetween; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other and defining the longitudinal edge extremities of the blank; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve as assembled and erected; said connecting panel and said first, second, third and fourth outer sleeve panels having the adjacent longitudinal edges thereof integrally joined by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve pan-el and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends of their respective score segments joined by cuts defining inwardly extending head tabs and alternating outwardly extending foot tabs of substantially equal transverse width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in spaced relation to the adjacent outer panels of the erected outer sleeve; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which extend inwardly of the blank and of lesser transverse width, by a width increment equal to the blank thickness, than the head and foot tabs associated with said Erst, second and third series of aligned score segments; the transverse width of said second inner sleeve panel, as defined between the first and second series of aligned score segments, being 'the same as the transverse Width of said fourth inner sleeve panel, as defined between the third and fourth series of aligned score segments; said first inner sleeve 4panel having a transverse width, as defined between its straight free edge and the first series of aligned score segments, which is lesser, by an increment substantially equal to the blank thickness, than the transverse width of the third inner sleeve panel as defined between the second and third series of aligned scored segments; whereby said free straight edge of said first inner sleeve panel will lie within the boundaries of the fourth inner sleeve panel and in 4adjacent but non-overlapping relation to the fourth series of aligned score segments when said second and first inner sleeve panels are folded along the second series of aligned score segments and into adjacent overlying relation with respect to said third and fourth inner sleeve panels, said connecting panel being divided, by a; longitudinally extending dividing score parallel to said continuous scores, into a Spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a securing section of lesser transverse width hinged by the adjacent continuous score to said first outer sleeve panel; said connecting panel dividing score having space cuts therein cf suficient number and length to break the resiliency of said dividing score; said connecting panel having a transverse width greater than the score-segment-defining width of said third inner sleeve panel but less than the continuous score-defining width of said second outer sleeve panel; said second inner sleeve panel having a maximum transverse width, as measured between the tip ends of its opposite foot and head tabs, which is substantially equal to the transverse inside Width of said first outer sleeve panel, as measured between its side edge defining scores; said fourth inner sleeve panel having a maximum transverse width, as measured between the tip ends of its opposite foot and head tabs, which is lesser, by a width increment equal to the thickness of the blank, than the transverse width of said third outer sleeve panel as measured between its side edge defining scores.

5. A one-piece, fibrous-sheet blank designed when assembled and erected to form a double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve; said blank presenting four inner sleeve forming panels and four outer sleeve forming panels and a connecting suspension panel therebetween; the first inner Sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other `and defining the longitudinal edge extremities of the blank; said first, second, third and fourth inner sleeve panels .and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve as assembled and erected; said connecting panel and said rst, second, third and fourth outer sleeve panels having the adjacent longitudinal edges thereof integrally joined by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said yfirst inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends 0f their respective score segments joined by cuts defining inwardly extending head tabs and `alternating outwardly extending foot tabs of substantially equal transverse width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in spaced relation to the adjacent outer panels of the erected outer sleeve; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which extend inwardly of the blank and of lesser transverse width, by a width increment equal -to the blank thickness, than the head and foot tabs associated with the said rst, second and third series of aligned score segments; the transverse width of said second inner sleeve panel as defined between the first and second series of aligned score segments being the same as the transverse width of said fourth inner sleeve panel as defined between the third and fourth series of aligned score segments; said first inner sleeve panel having a transverse width as defined between its straight free edge and the first series of aligned score segments, which is lesser, by `an increment substantially equal to the blank thickness, than the transverse Width of the third inner sleeve panel as defined between the second and third Series of aligned scored segments; whereby said free straight edge of said first inner sleeve panel will lie within the boundaries of the fourth inner sleeve panel and in adjacent but non-overlapping relation to the fourth series of aligned score segments when said second and first inner sleeve panels are folded along the second series of aligned score segments and into adjacent overlying relation with respect to said third and fourth inner sleeve panels; said aligned score segments and said continuous scores each being defined by a pair of adjacent parallel extending bend lines pressed into the outer face of the blank to provide therebetween a bead formation projecting from the inner face of the blank with the stock sheet fibers extending in a direction substantially transversely of the score segments; said connnecting panel being divided by a longitudinally extending dividing score parallel to said continuous scores, into a Spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a securing section of lesser transverse width hinged by the adjacent continuous score to said first outer sleeve panel; said connecting panel dividing score having space cuts therein of sufficient number and length to break the resiliency of said dividing score; said second inner sleeve panel having a maximum transverse width, as measured between the tip ends of its opposite foot and head tabs, which is substantially equal to the transverse inside width of said first outer sleeve panel as measured between its side edge defining scores; said fourth inner sleeve panel having a maximum transverse width, as measured between the tip ends of its opposite foot and head tabs, which is lesser, by a Width increment equal to the thickness of the blank, than the transverse width of said third outer sleeve panel as measured between its side edge defining scores.

6. A double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve and formed from a single blank of fibrous sheet material presenting four inner sleeve panels and four outer sleeve panels joined by a connecting panel, said inner and outer sleeves being erectable from collapsed position into substmtially rectangular form by the application of squeeze pressure only; the first inner sleeve panel and the fourth outer sleeve panel Veach having a free straight edge extending in parallel relation to each other; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve; said connecting panel and said first, second, third and fourth outer sleeve panels being integrally hinged along the adjacent longitudinal edges thereof by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third ser-ies of aligned score segments having the terminal ends of their respective score segments joined by cuts defining head tabs and foot tabs of substantially equal transverse width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in uniform spaced relation to the adjacent outer panels of the erected outer sleeve; said connecting panel being divided by a longitudinally extending dividing score into a Spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a securing section of lesser transverse width hinged by one of said continuous scores to the 'adjacent longitudinal outer edge of said first outer sleeve panel and adhesively secured to the inside face of said fourth outer sleeve panel Aadjacent the free straight edge thereof; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which dene head tabs only which project from. the adjacent side edge of said fourth inner sleeve panel to thereby maintain the adjacent side `edge of said Spanner section in space relation to the fourth outer sleeve panel of the erected outer sleeve; said last named head tabs being of lesser transverse width, by a Width increment equal to the blank thickness, than the head and foot tabs associated with said first, second and third series of aligned score segments; said Spanner section providing the sole support for the adjacent end of said fourth inner sleeve panel and being operative to suspend the adjacent end of said fourth inner sleeve panel in spaced relation to the third panel of the erected outer sleeve.

7. A double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve and formed from a single blank of fibrous sheet material presenting four inner sleeve panels and four outer sleeve panels joined by a connecting panel, said inner and outer sleeves being erectable from collapsed position into substantially rectangular form by the application of squeeze pressure only; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent innerface corners of the inner sleeve; said connecting panel and said first, second, third and fourth outer sleeve panels being integrally hinged along the adjacent longitudinal edges thereof by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends of their respective score segments joined by cuts defining head tabs and foot tabs of substantially equal transverse `width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in uniform spaced relation to the adjacent outer panels of the erected outer sleeve; said connecting panel being `divided by a llongitudinally extending ydividing score into a Spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a securing section of lesser transverse width hinged by one of said continuous scores to the adjacent longitudinal outer edge of said first outer sleeve panel and adhesively secured to the inside face of said fourth outer sleeve panel adjacent the straight free edge thereof; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which project from the adjacent side edge of said fourth inner sleeve panel to thereby maintain the adjacent side edge of said Spanner section in space relation to the fourth outer sleeve panel of the erected outer sleeve; said Llast named head tabs being of lesser transverse width, by a width increment equal to the blank thickness, than the head and foot tabs associated with said first, second and third series of aligned score segments; said Spanner section providing the sole support for the adjacent end of said fourth inner sleeve panel and being operative to suspend the adjacent end of said fourth inner sleeve panel in spaced relation to the third panel of the erected outer sleeve; the free straight edge of said first inner sleeve panel terminating adjacent to said fourth series of aligned score segments and being maintained in outswinging pressure contact with the adjacent side edge of said Spanner section by the inherent resiliency of said first series of aligned score segments; said inner sleeve as erected presenting smooth interior surfaces free of inwardly projecting and corners.

8. A double Walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve and formed from a single blank of fibrous sheet material presenting four inner sleeve panels and four outer sleeve panels joined by a connecting panel, said inner and outer sleeves being erectable from collapsed position into substantially rectangular form by the application of squeeze pressure only; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve; said connecting panel and said first, second, third and fourth outer sleeve panels being integrally hinged along the adjacent longitudinal edges thereof by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third series of aligned score segments having the terminal ends of their respective score segments joined by cuts defining head tabs and foot tabs of substantially equal transverse width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in uniform spaced relation to the adjacent outer panels of the erected outer sleeve; said connecting panel being divided by a longitudinally extending dividing score into a Spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a securing section of lesser transverse Width hinged by one of said continuous scores to the adjacent longitudinal outer edge of said first outer sleeve panel and adhesively secured to the inside face of said fourth panel of the outer sleeve; said connecting panel dividing score having spaced cuts therein of sufficient number and length to break the resiliency of said dividing score and permit said Spanner section to swing inwardly; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which project from the adjacent side edge of said fourth inner sleeve panel to thereby maintain the adjacent side edge of said Spanner section in spaced relation to the fourth outer sleeve panel of the erected outer sleeve; said last named head tabs being of lesser transverse width, by a Width increment equal to the blank thickness, than the head and foot tabs associated with said iirst, second and third series of aligned score segments; said spanner section providing the sole support for the adjacent end of said fourth inner sleeve panel and being operative to suspend the adjacent end of said fourth inner sleeve panel in spaced relation to the third panel of the erected outer sleeve; the free straight edge of said first inner sleeve panel terminating adjacent to said fourth series of aligned score segments and being maintained in outswinging pressure contact with the adjacent side edge of said Spanner section by the inherent resiliency of said first series of alici ed score segments; said inner sleeve as erected presenting smooth interior surfaces free of inwardly projecting edges and corners.

9. A double walled article cushioning carton having an inner sleeve interiorly of and in spaced relation to a protective outer sleeve and formed from a single blank of fibrous sheet material presenting four inner sleeve panels and four outer sleeve panels joined by a connecting panel, said inner and outer sleeves being erectable from collapsed position into substantially rectangular form by the application of squeeze pressure only; the first inner sleeve panel and the fourth outer sleeve panel each having a free straight edge extending in parallel relation to each other; said first, second, third and fourth inner sleeve panels and said connecting panel being integrally hinged along the adjacent longitudinal side edges thereof by a first, second, third and fourth series of spaced and aligned score segments which define the adjacent inner-face corners of the inner sleeve; said connecting panel and said first, second, third and fourth outer sleeve panels being integrally hinged along the `adjacent longitudinal edges thereof by continuous longitudinal scores extending in parallel relation to each other and in parallel relation to the free edges of said first inner sleeve panel and fourth outer sleeve panel and to the first, second, third and fourth series of aligned score segments; said first, second and third ser-ies of aligned score segments having the terminal ends of their respective score segments joined by cuts delining head tabs and foot tabs of substantially equal transverse Width and providing spacer elements operative to maintain the three adjacent corners of the erected inner sleeve in uniform spaced relation to the adjacent outer panels of the erected outer sleeve; said connecting panel being divided 'by a longitudinally extending dividing score into a Spanner section hinged by said fourth series of aligned score segments to said fourth inner sleeve panel and a lsecuring section of lesser transverse width hinged by one of said continuous scores to the adjacent longitudinal outer edge of said first outer sleeve panel and adhesively secured to the inside face of said fourth panel of the outer sleeve; said connecting panel dividing score having` spaced cuts therein of sufficient number and length to break the resiliency of said dividing score and permit said spanner section to swing inwardly; said fourth series of spaced score segments having the adjacent terminal ends thereof joined by cuts which define head tabs only which project from the adjacent side edge of said fourth inner sleeve panel to thereby maintain the adjacent side edge of said Spanner section in space relation to the fourth outer sleeve panel of the erected outer sleeve; said last named head tabs being of lesser transverse Width, by a Width increment equal to the blank thickness, than the head and foot tabs associated with said first, second and third series of aligned score segments; said spanner section providing the sole support for the adjacent end of said fourth inner sleeve panel and being operative to suspend the adjacent end of said fourth inner sleeve panel in spaced relation to the third panel of the erected outer sleeve; the free straight edge of said first inner sleeve panel terminating adjacent to said fourth series of aligned score segments and being maintained in outswinging pressure contact w-ith the adjacent side edge of said spanner section by the inherent resiliency of said first series of aligned score segments; inherent resiliency of said first series of aligned score segments being attained by so cutting the carton blank that the stock sheet fibers extend in a direction substantially transversely thereof; said inner sleeve as erected presenting smooth interior surfaces free of inwardly projecting edges and corners.

10. The method of making a collapsed double walled article-cushioning carton presenting when erected a substantially rectangular inner sleeve interiorly of and in spaced relation to a substantially rectangular protective outer sleeve; said method including, providing a blank of fibrous sheet material having straight and free longitudinal edges at opposite sides of the blank; defining the first, second, third and fourth inner sleeve panels by applying to the outer face of the blank a first, second, third and 17 fourth series of aligned score segments extending parallel to each other and longitudinally of the blank to thereby define the inner-face corners of the inner sleeve as assembled and erected; joining the terminal ends of said first, second and third series of aligned score segments by bowing cuts to define inwardly extending head tabs and alternating outwardly extending foot tabs of substantially equal transverse width and designed to provide the spacer elements for three corners of the erected inner Sleeve; connecting the terminal ends of said fourth series of aligned score segments by inwardly lbowing cuts only to provide head tabs of lesser transverse width than the head and foot tabs `associated with said first, second and third aligned score segments; -applying a series of ve transversely spaced continuous scores to the outside face of the blank which extends longitudinally thereof and in parallel relation to each other and to said score segments to thereby detine a connecting panel having a Spanner section and a securing section, and the first, second, third and fourth outer panels of the outer sleeve; said first, second, third and fourth series of aligned score segments being so transversely spaced that the transverse width of said second inner sleeve panel as defined between the iirst Vand second series of aligned score segments is the same as the transverse width of said fourth inner sleeve panel as defined between the third and fourth series of aligned score segments; and so that the transverse width of said first inner sleeve panel as deined between its straight yfree edge and the first series of aligned score segments is lesser, by an increment substantially equal to the blank thickness, than the transverse Width of the third inner sleeve panel as defined between the second and third series of aligned score segments; said continuous scores being transversely spaced so that said Spanner section is of greater width than said securing section but their combined transverse width is greater than the transverse width of said third inner sleeve panel but less than the transverse width of said second outer sleeve panel;

and so that said rst and third outer sleeve panels have substantially the same width; and so that the transverse width of said fourth outer sleeve panel is no greater than the transverse width of said second outer sleeve panel; and so that the transverse width of said second outer sleeve panel is substantially equal to the maximum transverse width of said third inner sleeve panel as defined between the tip ends of its opposite foot and head tabs; folding said second inner sleeve panel inwardly along said second series of aligned score segments so as to place said second and first inner sleeve panels in overlying relation to said third and fourth inner sleeve panels with the free straight edge of said iirst inner sleeve panel lying within the boundaries of said fourth inner sleeve panel and in adjacent but non-overlapping relation to the fourth series of aligned scored segments; folding said fourth inner sleeve panel along said fourth `series of aligned score segments so as to place said fourth and third inner sleeve panels in overlying relation to said connecting panel and said rst louter sleeve panel and with said lirst and second inner sleeve panels sandwiched therebetween; folding said first outer sleeve panel along said third continuous score so as to place said first outer sleeve panel and connecting panel in overlying relation to said second and third outer sleeve panels and with the third and fourth inner sleeve panels sandwiched therebetween, and with the shorter head tabs extending from said fourth series of aligned score seg-ments in non-overlapping relation to said fifth continuous score; applying adhesive to the outside face of said securing section only; and folding said fourth outer sleeve panel along said fth continuous score to place the same in overlying relation to said connecting panel and -in secured relation to the securing section thereof.

Tyrseck Dec. 5, 1950 McDonough Dec. 2, 1952 

